Method and apparatus for build surface support in additive manufacturing system

Abstract

A support for a build table for use with an additive manufacturing system. Two or more actuators may be coupled to the build table and configured to move the build table in a Z direction, e.g., for deposition of multiple precursor material layers, and rotate the build table about axes parallel to a build surface, e.g., to level the build surface. Couplings for one or more actuator may provide pivotal movement about at least two orthogonal axes and linear movement along only one direction parallel to the build surface.

1 . A support system for moving a build surface for an additive manufacturing system, the support system comprising:
 a build table having the build surface;   at least two actuators coupled to the build table and configured to move the build table in a Z direction; and   a coupling between each actuator and the build table, each coupling configured to provide pivotal movement about at least two orthogonal axes in a plane of the build table and to provide linear movement along only one direction parallel to the build surface.   
     
     
         2 . The system of  claim 1 , wherein the at least two actuators includes a first actuator having a first coupling between the first actuator and the build table, and a second actuator having a second coupling between the second actuator and the build table, the first coupling configured to provide linear movement along a first direction parallel to the build surface and the second coupling configured to provide linear movement along a second direction parallel to the build surface, the first and second directions being transverse to each other. 
     
     
         3 . The system of  claim 2 , wherein the first and second directions are configured to constrain movement of the build table in directions parallel a plane of the build surface. 
     
     
         4 . The system of  claim 2 , wherein the at least two actuators includes a third actuator having a third coupling between the third actuator and the build table, the third coupling configured to provide linear movement along a third direction parallel to the build surface, the first, second and third directions being transverse to each other. 
     
     
         5 . The system of  claim 4 , wherein the first, second and third directions are configured to constrain movement of the build table in directions parallel to a plane of the build surface. 
     
     
         6 . The system of  claim 5 , wherein the first, second and third directions lie in a common plane and are oriented at an angle of about 60 degrees relative to each other. 
     
     
         7 . The system of  claim 1 , wherein the at least two actuators are configured to move the build table in a Z direction for additive manufacturing of a part on the build table, and configured to rotate the build table about at least two transverse axes that are transverse to the Z direction to orient the build surface relative to a horizontal plane. 
     
     
         8 . The system of  claim 7 , wherein the at least two actuators includes three actuators. 
     
     
         9 . The system of  claim 8 , wherein the three couplings between each of the three actuators and the build table are coupled to the build table at the vertices of an equilateral triangle. 
     
     
         10 . A support system for leveling and raising a build surface for an additive manufacturing system, the support system comprising:
 a build table having the build surface; and   three actuators coupled to the build table and configured to move the build table in a Z direction for additive manufacturing of a part on the build table and configured to rotate the build table about at least two transverse axes that are transverse to the Z direction to orient the build surface relative to a horizontal plane.   
     
     
         11 . The system of  claim 10 , further comprising three couplings, each coupling between a corresponding actuator and the build table, and the three couplings each configured to permit rotation of the build table relative to the corresponding actuator about orthogonal axes in a plane of the build table. 
     
     
         12 . The system of  claim 11 , wherein the three couplings are configured to restrain movement of the build table in directions parallel to the build surface. 
     
     
         13 . The system of  claim 11 , wherein at least two of the three couplings are configured to provide pivotal movement about at least two orthogonal axes and linear movement along only one direction parallel to the build surface. 
     
     
         14 . The system of  claim 13 , wherein the three couplings include first and second couplings, the first coupling configured to provide linear movement along a first direction parallel to the build surface and the second coupling configured to provide linear movement along a second direction parallel to the build surface, the first and second directions being transverse to each other. 
     
     
         15 . The system of  claim 14 , wherein the three couplings includes a third coupling configured to provide linear movement along only a third direction parallel to the build surface, the first, second and third directions being transverse to each other. 
     
     
         16 . The system of  claim 15 , wherein the first, second and third directions are configured to constrain movement of the build table in a plane of the build surface. 
     
     
         17 . The system of  claim 10 , wherein the three actuators include first, second and third actuators that are coupled to the build table at respective first, second and third positions, the first, second and third positions being located at the vertices of an equilateral triangle. 
     
     
         18 . The system of  claim 10 , further comprising a recoater configured move along a recoater plane to flatten powdered material on the build surface, and wherein the three actuators are configured to rotate the build table about the at least two transverse axes to place the build surface in a plane parallel to the recoater plane. 
     
     
         19 . A method for additive manufacturing, the method comprising:
 moving a build table having a build surface in a Z direction using at least two actuators with a coupling between each actuator and the build table;   permitting pivotal movement between the build table and each coupling about at least two orthogonal axes in a plane of the build table; and   permitting linear movement between the build table and each coupling along only one direction parallel to the build surface.   
     
     
         20 . The method of  claim 19 , further comprising permitting linear movement along a first direction parallel to the build surface and permitting linear movement along a second direction parallel to the build surface, the first and second directions being transverse to each other. 
     
     
         21 . The method of  claim 20 , wherein the first and second directions constrain movement of the build table in directions parallel to the build surface. 
     
     
         22 . The method of  claim 20 , further comprising permitting linear movement along a third direction parallel to the build surface, the first, second and third directions being transverse to each other. 
     
     
         23 . The method of  claim 20 , wherein the first, second and third directions constrain movement of the build table in directions parallel to a plane of the build surface. 
     
     
         24 . The method of  claim 23 , wherein the first, second and third directions lie in a common plane and are oriented at an angle of about 60 degrees relative to each other. 
     
     
         25 . The method of  claim 24 , further comprising constraining movement of the build table in directions parallel to a plane of the build surface. 
     
     
         26 . The method of  claim 20 , further comprising rotating the build table about at least two transverse axes that are transverse to the Z direction to orient the build surface relative to a horizontal plane. 
     
     
         27 . The method of  claim 19 , further comprising fusing a precursor material disposed on the build surface with one or more laser energy pixels to form one or more parts on the build surface. 
     
     
         28 . A part manufactured using the method of  claim 19 . 
     
     
         29 . A method for leveling and raising a build surface for an additive manufacturing system, the method comprising:
 moving a build table having a build surface in a Z direction using three actuators; and   rotating the build table about at least two transverse axes that are transverse to the Z direction to orient the build surface relative to a horizontal plane using the three actuators.   
     
     
         30 . The method of  claim 29 , further comprising permitting rotation of the build table about orthogonal axes in a plane of the build table. 
     
     
         31 . The method of  claim 29 , further comprising flattening powdered material on the build surface using a recoater and rotating the build table about the at least two transverse axes to place the build surface in a plane parallel to the recoater plane. 
     
     
         32 . The method of  claim 29 , further comprising fusing a precursor material disposed on the build surface with one or more laser energy pixels to form one or more parts on the build surface. 
     
     
         33 . A part manufactured using the method of  claim 29 .